Water-resistant acrylic coatings

ABSTRACT

Water-resistant waterborne acrylic coating materials, systems and methods providing enhanced water resistance and durability are provided. Such coatings extend the service life of roofing systems that are exposed to ponding water and other extreme weather conditions. Coatings described herein exhibit superior water resistance attributes including one or more of water infiltration resistance, wet tensile strength and wet adhesion.

BACKGROUND

Among the most significant properties of commercial and residentialroofing systems is water resistance. The durability and service life ofroofing systems largely depends upon its ability to prevent waterinfiltration and to provide sustained mechanical properties, such as wettensile strength and wet adhesion, in applicable environmentalconditions. Ponding is the occurrence of water pooling on flat roofs orlocalized flat roofing sections from exposure to storms, snow melts,heavy rains or other wet conditions. Generally, conventional roofsystems are simply not designed to hold water for prolonged durations.Ponding water can collect dirt, which may cause the growth of vegetationand biofilm or telegraph mud cracking and chipping. It can also act as amagnifying glass on the roof under the pond, thus possibly increasingultraviolet exposure and causing localized damage. It can alsocontribute to photo-oxidation and resultant premature deterioration ofthe roof membrane, flashings and coatings. Ultimately, these and othereffects can lead to structural damage and possible roof collapse.

Waterborne roof coatings, most notably acrylic coatings, are commonlyused to extend roof service life. Acrylic coatings are eco-friendly andexhibit a combination of benefits including high reflectivity,re-coatability, good adhesion to multiple substrates and desirablemechanical properties. Failures of known acrylic coatings may includemicro-cracking, delamination or de-bonding, and biofilm attachment,which can lead to cracking, chipping, etc., and ultimately to structuraldamage of the underlying roof structure. One of the advantages of thecoating materials, systems and methods provided herein is to addressthese known failures by providing acrylic coating systems that areresistant to ponding water failures while retaining the benefits ofwaterborne coatings.

SUMMARY

Described herein are water-resistant waterborne acrylic coatingmaterials, systems and methods providing enhanced water resistance anddurability. Such coatings extend the service life of roofing systemsthat are exposed to ponding water and other extreme weather conditions.Coatings described herein exhibit superior water resistance attributesincluding one or more of water infiltration resistance, wet tensilestrength and wet adhesion. Resultant coatings are resistant to pondingwater failures upon long-term exposure to standing water environment,wet-dry cycling and other thermal cycle stresses.

In one aspect, a coating material is provided, which is suitable forapplication to a roofing substrate, among other uses. In certainembodiments, the coating material comprises at least one acrylic latexresin, at least one functional filler, and at least one hydrophobicadditive.

In certain embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a waterinfiltration depth of about 120 microns or less after 4 hours at 60° C.and 95% relative humidity.

In certain embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a wet tensilestrength of at least about 80 psi as measured according to ASTM D882and/or ASTM D2370. In embodiments, when the coating material is appliedas a coating to the roofing substrate, the coating exhibits a wettensile strength of about 80 psi to about 500 psi as measured accordingto ASTM D882 and/or ASTM D2370. In embodiments, when the coatingmaterial is applied as a coating to the roofing substrate, the coatingexhibits a wet tensile strength of about 85 psi to about 500 psi asmeasured according to ASTM D882 and/or ASTM D2370. In embodiments, whenthe coating material is applied as a coating to the roofing substrate,the coating exhibits a wet tensile strength of about 90 psi to about 500psi as measured according to ASTM D882 and/or ASTM D2370. Inembodiments, when the coating material is applied as a coating to theroofing substrate, the coating exhibits a wet tensile strength of about95 to about 500 psi as measured according to ASTM D882 and/or ASTMD2370.

In certain embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a wet adhesion ofat least about 2 pli (pounds per linear inch) as measured according toASTM D903. In embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a wet adhesion ofabout 2 pli to about 15 pli as measured according to ASTM D903. Inembodiments, when the coating material is applied as a coating to theroofing substrate, the coating exhibits a wet adhesion of about 3 pli toabout 15 pli as measured according to ASTM D903. In embodiments, whenthe coating material is applied as a coating to the roofing substrate,the coating exhibits a wet adhesion of about 4 pli to about 15 pli asmeasured according to ASTM D903. In embodiments, when the coatingmaterial is applied as a coating to the roofing substrate, the coatingexhibits a wet adhesion of about 5 pli to about 15 pli as measuredaccording to ASTM D903. In embodiments, when the coating material isapplied as a coating to the roofing substrate, the coating exhibits awet adhesion of about 6 pli to about 15 pli as measured according toASTM D903. In embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a wet adhesion ofabout 7 pli to about 15 pli as measured according to ASTM D903. Inembodiments, when the coating material is applied as a coating to theroofing substrate, the coating exhibits a wet adhesion of about 8 pli toabout 15 pli as measured according to ASTM D903. In embodiments, whenthe coating material is applied as a coating to the roofing substrate,the coating exhibits a wet adhesion of about 9 pli to about 15 pli asmeasured according to ASTM D903. In embodiments, when the coatingmaterial is applied as a coating to the roofing substrate, the coatingexhibits a wet adhesion of about 10 pli to about 15 pli as measuredaccording to ASTM D903. In embodiments, when the coating material isapplied as a coating to the roofing substrate, the coating exhibits awet adhesion of about 11 pli to about 15 pli as measured according toASTM D903. In embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a wet adhesion ofabout 12 pli to about 15 pli as measured according to ASTM D903. Inembodiments, when the coating material is applied as a coating to theroofing substrate, the coating exhibits a wet adhesion of about 13 plito about 15 pli as measured according to ASTM D903. In embodiments, whenthe coating material is applied as a coating to the roofing substrate,the coating exhibits a wet adhesion of about 14 pli to about 15 pli asmeasured according to ASTM D903.

In certain embodiments, the acrylic latex resin is selected from thegroup consisting of hydrophobic resins, self-crosslinking resins, andcrosslinkable resins.

In certain embodiments, the content of the at least one acrylic latexresin within the coating material is about 20-70 weight percent. Inother embodiments, the content of the at least one acrylic latex resinwithin the coating material is about 30-70 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 40-70 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 50-70 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 20-60 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 20-50 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 20-40 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 20-30 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 25-65 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 30-60 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 35-55 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 35-50 weight percent.

In certain embodiments, the content of at least one functional fillerwithin the coating material is about 10-50 weight percent. In otherembodiments, the content of at least one functional filler within thecoating material is about 10-40 weight percent. In other embodiments,the content of at least one functional filler within the coatingmaterial is about 10-30 weight percent. In other embodiments, thecontent of at least one functional filler within the coating material isabout 10-20 weight percent. In other embodiments, the content of atleast one functional filler within the coating material is about 20-50weight percent. In other embodiments, the content of at least onefunctional filler within the coating material is about 30-50 weightpercent. In other embodiments, the content of at least one functionalfiller within the coating material is about 40-50 weight percent. Inother embodiments, the content of at least one functional filler withinthe coating material is about 15-45 weight percent. In otherembodiments, the content of at least one functional filler within thecoating material is about 20-45 weight percent. In other embodiments,the content of at least one functional filler within the coatingmaterial is about 25-45 weight percent. In other embodiments, thecontent of at least one functional filler within the coating material isabout 30-45 weight percent. In other embodiments, the content of atleast one functional filler within the coating material is about 35-40weight percent.

In certain embodiments, the functional filler is selected from the groupconsisting of silicate minerals, silica, wollastonite (calciuminosilicate mineral CaSiO₃), talc, mica, kaolin, feldspar, nephelinesyenite, nanoclays, platy fillers, nano-oxide materials, calciumcarbonate, aluminum hydroxide, magnesium hydroxide, aluminum tryhydrate,basalt, zinc oxide, barium sulfate, and combinations thereof. In certainembodiments, the functional filler is characterized by a high aspectratio, which can enhance tensile strength of the coating material whileretaining water infiltration resistance and wet adhesion. Inembodiments, the aspect ratio of the functional filler is about 3-100.In embodiments, the aspect ratio of the functional filler is about5-100. In embodiments, the aspect ratio of the functional filler isabout 10-100. In embodiments, the aspect ratio of the functional filleris about 15-100. In embodiments, the aspect ratio of the functionalfiller is about 20-100. In embodiments, the aspect ratio of thefunctional filler is about 25-100. In embodiments, the aspect ratio ofthe functional filler is about 30-100. In embodiments, the aspect ratioof the functional filler is about 35-100. In embodiments, the aspectratio of the functional filler is about 40-100. In embodiments, theaspect ratio of the functional filler is about 45-100. In embodiments,the aspect ratio of the functional filler is about 50-100. Inembodiments, the aspect ratio of the functional filler is about 55-100.In embodiments, the aspect ratio of the functional filler is about60-100. In embodiments, the aspect ratio of the functional filler isabout 65-100. In embodiments, the aspect ratio of the functional filleris about 70-100. In embodiments, the aspect ratio of the functionalfiller is about 75-100. In embodiments, the aspect ratio of thefunctional filler is about 80-100. In embodiments, the aspect ratio ofthe functional filler is about 85-100. In embodiments, the aspect ratioof the functional filler is about 90-100. In embodiments, the aspectratio of the functional filler is about 95-100. In embodiments, thefunctional filler is a high aspect ratio filler comprising wollastonite,talc, clays and/or mica. The inventors have found that when embodimentsof the coating material containing one or more functional fillers havingan aspect ratio of about 3-100 are applied as a 500 micron dry filmthickness coating to a roofing substrate, the coating exhibits a greaterdry tensile strength than a test coating on a roofing substrate appliedwith an identical coating material without the one or more functionalfillers having an aspect ratio of about 3-100.

In certain embodiments, the content of at least one hydrophobic additiveis about 0.5-20 weight percent. In other embodiments, the content of atleast one hydrophobic additive is about 0.5-10 weight percent. In otherembodiments, the content of at least one hydrophobic additive is about1-5 weight percent. In other embodiments, the content of at least onehydrophobic additive is about 1-3 weight percent. In other embodiments,the content of at least one hydrophobic additive is about 1-2 weightpercent.

In certain embodiments, the hydrophobic additive is selected from thegroup consisting of hydrophobic copolymer dispersants and salts thereof,nonionic rheology modifiers, PTFE powders, silicone surface additive,polyolefin powder with having molecular weight within the range100,000-1,000,000 Daltons, polyolefin wax and hydrophobic waxdispersions.

In certain embodiments, coating material further comprises a pigment. Incertain of these embodiments, the content of the pigment is 2-15 weightpercent. In other embodiments, the content of the pigment is 3-15 weightpercent. In other embodiments, the content of the pigment is 4-15 weightpercent. In other embodiments, the content of the pigment is 5-15 weightpercent. In other embodiments, the content of the pigment is 6-15 weightpercent. In other embodiments, the content of the pigment is 7-15 weightpercent. In other embodiments, the content of the pigment is 8-15 weightpercent. In other embodiments, the content of the pigment is 9-15 weightpercent. In other embodiments, the content of the pigment is 10-15weight percent. In other embodiments, the content of the pigment is11-15 weight percent. In other embodiments, the content of the pigmentis 12-15 weight percent. In other embodiments, the content of thepigment is 13-15 weight percent. In other embodiments, the content ofthe pigment is 14-15 weight percent. In other embodiments, the contentof the pigment is 2-14 weight percent. In other embodiments, the contentof the pigment is 2-13 weight percent. In other embodiments, the contentof the pigment is 2-12 weight percent. In other embodiments, the contentof the pigment is 2-11 weight percent. In other embodiments, the contentof the pigment is 2-10 weight percent. In other embodiments, the contentof the pigment is 2-9 weight percent. In other embodiments, the contentof the pigment is 2-8 weight percent. In other embodiments, the contentof the pigment is 2-7 weight percent. In other embodiments, the contentof the pigment is 2-6 weight percent. In other embodiments, the contentof the pigment is 2-5 weight percent. In other embodiments, the contentof the pigment is 2-4 weight percent. In other embodiments, the contentof the pigment is 2-3 weight percent.

In certain embodiments, coating material further comprises acrosslinking agent. In another aspect, a coating system is provided thatcomprises a roofing substrate and a coating material at least partiallycoating the roofing substrate, wherein the coating material comprises atleast one acrylic latex resin, at least one functional filler, and atleast one hydrophobic additive. The roofing substrate comprises anysuitable material or structure used in commercial or residential roofingapplications, including underlayment and flashing.

In yet another aspect, a coating method is provided that comprises theapplication of a coating material to a roofing substrate, where thecoating material comprises at least one acrylic latex resin, at leastone functional filler, and at least one hydrophobic additive.

DETAILED DESCRIPTION

The coating materials provided herein generally comprise at least oneacrylic latex resin, at least one functional filler, and at least onehydrophobic additive. The inventors have found that such materialsexhibit superior water resistance properties, including preventing waterinfiltration while providing high wet tensile strength and wet adhesion,thus providing durable roofing systems even under ponding conditionswhen applied to roofing substrates.

The acrylic latex resins used in embodiments described herein includehydrophobic resins, self-crosslinking resins, and/or crosslinkableresins. Examples of commercially-available self-crosslinking acrylicsinclude Acronal® (BASF SE European Company) 4848, Ecronova® (MallardCreek Polymers, Inc.) series such as grade 6608, Centurion® (The DowChemical Company), and UCAR™ (Arkema Inc.) Latex 9176. Examples ofcrosslinkable acrylics include Acrylics Rovene® (Mallard Creek Polymers,Inc.) 6119, acrylic resin grades with carboxylic acid end groups and anacid number (e.g. >8 mg/100 g), and Asahi Polydurex B3120 acrylic-silanecore-shell hybrid. Examples of hydrophobic resins include Syntran®(Interpolymer Corporation) 6211, Rovene® (Mallard Creek Polymers, Inc.)6120, and Neocar® (Arkema Inc.) 820, 2300, 850. Where crosslinkableresins are used, embodiments may optionally include one or more knownchemical crosslinking agents such as carbodiimide such as Carbodilite®(Nisshinbo Holdings Inc.) and water stable epoxy silane such asCoatosil® (Momentive Performance Materials Inc.) 2287.

The functional fillers used in embodiments described herein provideenhanced properties such as tensile, water resistance and adhesionproperties. Examples of such fillers include silicate minerals, silica,wollastonite, talc, mica, kaolin, feldspar, and nepheline syenite,surface treated fillers and sub-micron fillers such as nanoclays, platyfillers and nano-oxides commonly used in anti-corrosion coatings.Without wishing to be bound by theory, the inventors believe that theincorporation of the nano-fillers creates a tortuous pathway for waterpermeation, limiting water absorption and adverse solvation effect onthe coating. Examples of surface treated fillers include calciumcarbonates, Camel-Wite™ ST (Imerys), aluminum trihydrate (lowsolubility) such as Hymod® (J. M. Huber Corporation) Micral grades, andHymod M9400 SG & Hymod SB432-SG-surface treated grade. Other functionalfillers are hydrophobic in nature and include Novakup® and Novacite®(Malvern Minerals Company) platy silica, treated and non-treated fumedsilicas, Aerosil® (Evonik Degussa GmbH), Oxylink™ (MicronisersAustralasia Pty Ltd.), pre-dispersed nano ZnO₂, and nano-kaolin,-bentonite, and -monomonilorite clays.

The hydrophobic additives used in embodiments described herein includeTamol® (Rohm and Haas Company) 165A, 731, 2011 and 2001, Disperbyk®(BYK-Chemie GMBH Ltd) 2013, 2015, and 099 and HUER thickeners (NonionicPolyurethane Associative Thickeners) such as Acrysol® (Rohn and HaasCompany) Rm-12w, 8W, 2020, and 995, and Dow Rheolate series, RM-12w,RM-995, RM-8W, and RM-2020NPR, PTFE micro powders for addedhydrophobicity, SST®-3 (Shamrock Technologies, Inc.) micro PTFE,hydrophobic wax dispersions, and Ultralube® (Keim-Additec Surface GmbH)E-360 Modified paraffin.

In certain embodiments, the content of the at least one acrylic latexresin within the coating material is about 20-70 weight percent. Inother embodiments, the content of the at least one acrylic latex resinwithin the coating material is about 30-70 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 40-70 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 50-70 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 20-60 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 20-50 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 20-40 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 20-30 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 25-65 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 30-60 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 35-55 weight percent. In otherembodiments, the content of the at least one acrylic latex resin withinthe coating material is about 35-50 weight percent.

In certain embodiments, the content of at least one functional fillerwithin the coating material is about 10-50 weight percent. In otherembodiments, the content of at least one functional filler within thecoating material is about 10-40 weight percent. In other embodiments,the content of at least one functional filler within the coatingmaterial is about 10-30 weight percent. In other embodiments, thecontent of at least one functional filler within the coating material isabout 10-20 weight percent. In other embodiments, the content of atleast one functional filler within the coating material is about 20-50weight percent. In other embodiments, the content of at least onefunctional filler within the coating material is about 30-50 weightpercent. In other embodiments, the content of at least one functionalfiller within the coating material is about 40-50 weight percent. Inother embodiments, the content of at least one functional filler withinthe coating material is about 15-45 weight percent. In otherembodiments, the content of at least one functional filler within thecoating material is about 20-45 weight percent. In other embodiments,the content of at least one functional filler within the coatingmaterial is about 25-45 weight percent. In other embodiments, thecontent of at least one functional filler within the coating material isabout 30-45 weight percent. In other embodiments, the content of atleast one functional filler within the coating material is about 35-40weight percent.

In certain embodiments, the content of at least one hydrophobic additiveis about 0.5-20 weight percent. In other embodiments, the content of atleast one hydrophobic additive is about 0.5-10 weight percent. In otherembodiments, the content of at least one hydrophobic additive is about1-5 weight percent. In other embodiments, the content of at least onehydrophobic additive is about 1-3 weight percent. In other embodiments,the content of at least one hydrophobic additive is about 1-2 weightpercent.

The coating materials provided herein optionally comprise pigmentmaterials such as titanium dioxide particles. In certain of theseembodiments, the content of the pigment is 2-15 weight percent. In otherembodiments, the content of the pigment is 3-15 weight percent. In otherembodiments, the content of the pigment is 4-15 weight percent. In otherembodiments, the content of the pigment is 5-15 weight percent. In otherembodiments, the content of the pigment is 6-15 weight percent. In otherembodiments, the content of the pigment is 7-15 weight percent. In otherembodiments, the content of the pigment is 8-15 weight percent. In otherembodiments, the content of the pigment is 9-15 weight percent. In otherembodiments, the content of the pigment is 10-15 weight percent. Inother embodiments, the content of the pigment is 11-15 weight percent.In other embodiments, the content of the pigment is 12-15 weightpercent. In other embodiments, the content of the pigment is 13-15weight percent. In other embodiments, the content of the pigment is14-15 weight percent. In other embodiments, the content of the pigmentis 2-14 weight percent. In other embodiments, the content of the pigmentis 2-13 weight percent. In other embodiments, the content of the pigmentis 2-12 weight percent. In other embodiments, the content of the pigmentis 2-11 weight percent. In other embodiments, the content of the pigmentis 2-10 weight percent. In other embodiments, the content of the pigmentis 2-9 weight percent. In other embodiments, the content of the pigmentis 2-8 weight percent. In other embodiments, the content of the pigmentis 2-7 weight percent. In other embodiments, the content of the pigmentis 2-6 weight percent. In other embodiments, the content of the pigmentis 2-5 weight percent. In other embodiments, the content of the pigmentis 2-4 weight percent. In other embodiments, the content of the pigmentis 2-3 weight percent.

In some embodiments, the coating material has a wet tensile strength ofat least about 80 psi as measured according to ASTM D882 and/or ASTMD2370.

Coatings made from the coating materials described herein provideexcellent resistance against water infiltration. In some embodiments,when the coating material is applied as a coating to the roofingsubstrate, the coating exhibits a water infiltration depth after 4 hoursat 60° C. and 95% relative humidity of about 120 microns or less in someembodiment, about 100 microns or less in other embodiments, about 75microns or less in other embodiments, about 55 microns or less in otherembodiments, and about 35 microns or less in other embodiments. When thecoating material is applied as a coating to the roofing substrate, thecoating exhibits a wet tensile strength as measured according to ASTMD882 and/or ASTM D2370 of at least about 80 psi in some embodiments, atleast 95 psi in other embodiments, and at least 105 psi in otherembodiments, at least 120 psi in other embodiments, and at least 130 psiin other embodiments. When the coating material is applied as a coatingto the roofing substrate, the coating exhibits a wet adhesion of atleast about 2 pli (pounds per linear inch) as measured according to ASTMD903 in some embodiments. In embodiments, when the coating material isapplied as a coating to the roofing substrate, the coating exhibits awet adhesion of about 2 pli to about 15 pli as measured according toASTM D903. In embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a wet adhesion ofabout 3 pli to about 15 pli as measured according to ASTM D903. Inembodiments, when the coating material is applied as a coating to theroofing substrate, the coating exhibits a wet adhesion of about 4 pli toabout 15 pli as measured according to ASTM D903. In embodiments, whenthe coating material is applied as a coating to the roofing substrate,the coating exhibits a wet adhesion of about 5 pli to about 15 pli asmeasured according to ASTM D903. In embodiments, when the coatingmaterial is applied as a coating to the roofing substrate, the coatingexhibits a wet adhesion of about 6 pli to about 15 pli as measuredaccording to ASTM D903. In embodiments, when the coating material isapplied as a coating to the roofing substrate, the coating exhibits awet adhesion of about 7 pli to about 15 pli as measured according toASTM D903. In embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a wet adhesion ofabout 8 pli to about 15 pli as measured according to ASTM D903. Inembodiments, when the coating material is applied as a coating to theroofing substrate, the coating exhibits a wet adhesion of about 9 pli toabout 15 pli as measured according to ASTM D903. In embodiments, whenthe coating material is applied as a coating to the roofing substrate,the coating exhibits a wet adhesion of about 10 pli to about 15 pli asmeasured according to ASTM D903. In embodiments, when the coatingmaterial is applied as a coating to the roofing substrate, the coatingexhibits a wet adhesion of about 11 pli to about 15 pli as measuredaccording to ASTM D903. In embodiments, when the coating material isapplied as a coating to the roofing substrate, the coating exhibits awet adhesion of about 12 pli to about 15 pli as measured according toASTM D903. In embodiments, when the coating material is applied as acoating to the roofing substrate, the coating exhibits a wet adhesion ofabout 13 pli to about 15 pli as measured according to ASTM D903. Inembodiments, when the coating material is applied as a coating to theroofing substrate, the coating exhibits a wet adhesion of about 14 plito about 15 pli as measured according to ASTM D903.

EXAMPLES

Embodiments of the invention are described with reference to thefollowing non-limiting examples. Samples 1-12 were formulated and testedfor various mechanical properties as described herein.

Coating formulations were prepared as follows. The grind stage wasprepared by adding the water, dispersing agent and wetting agenttogether and combining. The fillers were then added in stages with short30 second cycles at 1200 rpm in a counter-rotating planetary speedmixer. The pigment (TiO₂) and pigment extender were added together andmixed. The calcium carbonate was then added in two stages. Finally,defoamer and any thickener were added with light stirring and speedmixed for 45 seconds. Once checked for homogeneity, the grind stage wasmixed at 1600 rpm for 3 minutes to ensure full dispersion. The letdownstage was performed in a standard high-speed disperser with a Cowlesstyle blade, and each addition was done in rank order shown toincorporate fully before the next addition. Alternatively, similarresults were attained by thoroughly hand-stirring each additive into thebatch with a spatula and performing a final speed mix of 1 minute at1200 rpm. Batches were allowed to sit overnight at ambient temperaturesin their sealed containers. All batches were speed mixed at 1200 rpm for1 minute under 26 in Hg of vacuum to de-air the coating before filmswere drawn down.

Wet tensile testing was performed according to ASTM D882 and/or ASTMD2370 after 24 hours at 72° F. immersion in water. All samples were cutusing a six cell die of sample dimensions 0.5″×3″. Samples were handledand measured while wet, and blotted dry just before testing.

Water infiltration testing was performed on 2″ diameter samples of a 500micron dry film thickness (dft) coating film placed on a 2″ outerdiameter Quick-Clamp Sanitary Tube Fitting placed on top of a metal meshset in a sample tray to allow for air flow to bottom of membrane. About20 ml of 1% Methylene Blue solution was pipetted into the top section ofthe fitting. Each sample on its tray was then placed into a stabilitychamber set to 60° C. at 95% relative humidity for 4 hours. The samplejig was then drained of dye solution, blotted dry and the samples wereremoved and allowed to cool and dry. Each sample was cut evenly in halfwith a clean sharp razor blade. Samples were mounted into a micro viseedge up and cross sections were viewed at 200× magnification. The totalfilm thickness and average depth of dye penetration were measuredoptically and recorded.

For wet adhesion testing, samples were prepared by creating a total of500 micron dry film thickness (dft) film with an embedment of areinforcement in size, 5 inches wide and 11 inches long. Samples weredrawn down on a 6 inch-by-6 inch sample of 45 mil TPO with TPO RedPrimer (GAF Materials Corporation). Silicone caulk was used to seal alledges to prevent lateral water infiltration. The cured samples wereplaced in pans filled with 1-1.5 inches of deionized water and allowedto rest either at room temperature or at 60° C. for 7 days. The water inthe pan was then drained and the samples were tested as per ASTM D903.

Table I provides compositional information for Samples 1-12, and TableII provides test results.

TABLE I Sample compositions (in weight percent). Hydrophobic Sample #Resin Filler Additive Pigment Other 1 (comparative) 42% 36.5% None 6.1%10.2% water, (Acronal (CaCO₃) (TiO₂) 0.57% propylene 4848) glycol, 0.46%AntiTerra 250, 0.12% potassium tri-polyphosphate, other inactiveingredients to balance 7 (comparative) 41.7% 35.9% 1.36% (Tamol 6.1%12.2% water, other (Acronal (CaCO₃ + 901A + (TiO₂) inactive ingredientsNX3250M) SB-432) Rheolate 1) to balance 9 (comparative) 43.6% 36.5%0.65% Tamol 6.7% 10.4% water, other Rovene CaCO₃ 165A + (TiO₂) inactiveingredients 6120 Acrysol to balance (other RM-8W may includesurfactants, rheological modifiers, pH modifiers, defoamers) 11(comparative)  43.4% 36.5% ATH 0.95% Tamol 6.7% 10.2% water, otherRovene 165A + (TiO₂) inactive ingredients 6120 Acrysol to balance RM-8W2 42% 36.5% 1.45% (Tamol 6.8% 10.3% water, (Acronal (CaCO₃) 165A +(TiO₂) 0.57% propylene 4848) Acrysol glycol, other RM-8W) inactiveingredients to balance 3 35.6% 36.4% 8.22% (Tamol 6.7% 10.0% water,(Acronal (CaCO₃) 165A + (TiO₂) 0.55% propylene 4848) Acrysol glycol,other RM-8W + inactive ingredients APS-254) to balance 4 41.4% 36.5%1.25% (Tamol 6.8% 10.5% water, (Syntran (CaCO₃) 165A + (TiO₂) 0.55%propylene 6211) Acrysol glycol, other RM-8W) inactive ingredients tobalance 5 42.3% 36.4% 0.97% (Tamol 6.7% 9.97% water, (Syntran Camel Wite165A + (TiO₂) 0.55% propylene 6211) ST Acrysol glycol, other RM-8W)inactive ingredients to balance 6 27.3% 36.5% 15.9% (Tamol 6.7% 10.0%water, (Syntran (CaCO₃) 165A + (TiO₂) 0.55% propylene 6211) Acrysolglycol, other RM-8W + inactive ingredients Carapol to balance AAR-127) 842% 36.7% 1.05% (Tamol 6.7% 9% water, 0.57% (Acronal (CaCO₃ + 165A +(TiO₂) propylene glycol, NX3250M) SB-432 + Acrysol 0.3% Carbodilite E-Oxylink RM-8W + 05 (crosslinker) 3101) Acrysol RM- 2020) 10  43.4% 32.9%0.7% Tamol 6.7% 10.4% water, other Rovene CaCO3 and 165A + (TiO₂)inactive ingredients 6120 3.7% Acrysol to balance Wollastonite RM-8W 12 42.9% 29.2% ATH 1% Tamol 6.7% 10.41% water, other Rovene and 7.3% 165A +(TiO₂) inactive ingredients 6120 Wollastonite Acrysol to balance RM-8W

TABLE II Sample properties (note that Sample numbers correspond with thecompositions shown in Table I). Water Dry tensile Wet tensileinfiltration 60° C. Wet Sample # strength (psi) strength (psi) (microns)adhesion, pli 1 (comparative) 184 56 158 7.5 7 (comparative) 158 21 388n/a 9 (comparative) 181 88 41 3.6 11 (comparative)  185 108 72 3.4 2 19692 118 7.4 3 180 97 54 4.6 4 260 87 44 2.6 5 327 95 28 6.6 6 246 85 20 28 192 70 71 n/a 10  247 93 40 2.8 12  251 130 66 3.7

Several observations can be drawn from inspection of Tables I and II.Samples 2 and 3 illustrate the improvement to water infiltrationresistance and wet tensile strength compared with Comparative Sample 1.The improvements are believed to result from the use of hydrophobicadditives. Samples 5 and 6 illustrate further improvements to the wettensile strength and/or water infiltration properties of Sample 4, whichis based upon a hydrophobic acrylic with high water infiltrationresistance. Sample 5 makes use of Camel White™ ST (Imerys), a fineparticle size, wet ground white calcitic marble. Sample 6 contains 15 wt% CaraPol AAR-127 as an additional hydrophobic additive. Sample 8 showsa significant improvement over Comparative Sample 7 in wet tensilestrength and water infiltration resistance from the addition ofnanofiller Oxylink as a functional filler, and crosslinking agentCarbodilite E-05. Sample 10 contains a blend of calcium carbonate and3.7% wollastonite filler and shows a 36% increase in dry tensilestrength relative to the comparative example 9 with only calciumcarbonate. Sample 12 contains a blend of hydrophobically modified ATHand 7.3% wollastonite and shows a 36% increase in dry tensile strengthand a 20% increase in wet tensile strength relative to the comparativeexample 11 with only hydrophobically modified ATH.

Conventional terms in the fields of materials science and engineeringhave been used herein. The terms are known in the art and are providedonly as a non-limiting example for convenience purposes. Accordingly,the interpretation of the corresponding terms in the claims, unlessstated otherwise, is not limited to any particular definition. Thus, theterms used in the claims should be given their broadest reasonableinterpretation.

Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat any arrangement that is adapted to achieve the same purpose may besubstituted for the specific embodiments shown. Many adaptations will beapparent to those of ordinary skill in the art. Accordingly, thisapplication is intended to cover any adaptations or variations.

The above detailed description includes references to the accompanyingdrawings, which form a part of the detailed description. The drawingsshow, by way of illustration, specific embodiments that may bepracticed. These embodiments are also referred to herein as “examples.”Such examples may include elements in addition to those shown ordescribed. However, the present inventors also contemplate examples inwhich only those elements shown or described are provided. Moreover, thepresent inventors also contemplate examples using any combination orpermutation of those elements shown or described (or one or more aspectsthereof), either with respect to a particular example (or one or moreaspects thereof), or with respect to other examples (or one or moreaspects thereof) shown or described herein.

All publications, patents, and patent documents referred to in thisdocument are incorporated by reference herein in their entirety, asthough individually incorporated by reference. In the event ofinconsistent usages between this document and those documents soincorporated by reference, the usage in the incorporated reference(s)should be considered supplementary to that of this document; forirreconcilable inconsistencies, the usage in this document controls.

In this document, the terms “a” or “an” are used, as is common in patentdocuments, to include one or more than one, independent of any otherinstances or usages of “at least one” or “one or more.” In thisdocument, the term “or” is used to refer to a nonexclusive or, such that“A or B” includes “A but not B,” “B but not A,” and “A and B,” unlessotherwise indicated. In this document, the terms “including” and “inwhich” are used as the plain-English equivalents of the respective terms“comprising” and “wherein.” Also, in the following claims, the terms“including” and “comprising” are open-ended, that is, a system, device,article, or process that includes elements in addition to those listedafter such a term in a claim are still deemed to fall within the scopeof that claim. Moreover, in the following claims, the terms “first,”“second,” and “third,” etc. are used merely as labels, and are notintended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and notrestrictive. For example, the above-described examples (or one or moreaspects thereof) may be used in combination with each other. Otherembodiments may be used, such as by one of ordinary skill in the artupon reviewing the above description. The Abstract is provided to complywith 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain thenature of the technical disclosure and is submitted with theunderstanding that it will not be used to interpret or limit the scopeor meaning of the claims.

In this Detailed Description, various features may have been groupedtogether to streamline the disclosure. This should not be interpreted asintending that an unclaimed disclosed feature is essential to any claim.Rather, inventive subject matter may lie in less than all features of aparticular disclosed embodiment. Thus, the following claims are herebyincorporated into the Detailed Description, with each claim standing onits own as a separate embodiment, and it is contemplated that suchembodiments may be combined with each other in various combinations orpermutations. The scope of the embodiments should be determined withreference to the appended claims, along with the full scope ofequivalents to which such claims are entitled.

1. A coating material, comprising: at least one acrylic latex resin; atleast one functional filler; at least one hydrophobic additive; and acrosslinking agent; wherein the acrylic latex resin is selected from thegroup consisting of hydrophobic resins, self-crosslinking resins, andcrosslinkable resins; and wherein, when the coating material is appliedas a 500 micron dry film thickness coating to a roofing substrate, thecoating exhibits a water infiltration depth of 120 microns or less after4 hours at 60° C. and 95% relative humidity.
 2. The coating material ofclaim 1, wherein the functional filler is selected from the groupconsisting of silicate minerals, silica, wollastonite, talc, mica,kaolin, feldspar, nepheline syenite, nanoclays, platy fillers,nano-oxide materials, calcium carbonate, aluminum hydroxide, magnesiumhydroxide, aluminum tryhydrate, barium sulfate, basalt, zinc oxide, andcombinations thereof.
 3. The coating material of claim 1, wherein thehydrophobic additive is selected from the group consisting ofhydrophobic copolymer dispersants and salts thereof, nonionic rheologymodifiers, PTFE powders, silicone surface additive, high molecularweight polyolefin powder, polyolefin wax and hydrophobic waxdispersions.
 4. The coating material of claim 1, wherein the content ofthe at least one acrylic latex resin is 20-70 weight percent.
 5. Thecoating material of claim 1, wherein the content of the at least onefunctional filler is 25-65 weight percent.
 6. The coating material ofclaim 1, wherein the content of the at least one hydrophobic additive is0.5-20 weight percent.
 7. The coating material of claim 1, furthercomprising a pigment.
 8. The coating material of claim 7, wherein thecontent of the pigment is 2-15 weight percent.
 9. (canceled)
 10. Thecoating material of claim 1, wherein the coating has a wet tensilestrength of at least 80 psi as measured according to ASTM D882 and/orASTM D2370.
 11. A coating material, comprising: an acrylic latex resin;a functional filler; a hydrophobic additive; and a crosslinking agent;wherein the acrylic latex resin is selected from the group consisting ofhydrophobic resins, self-crosslinking resins, and crosslinkable resins;and wherein, when the coating material is applied as a coating to aroofing substrate, the coating has a wet tensile strength of 80 psi to500 psi as measured according to ASTM D882 and/or ASTM D2370.
 12. Thecoating material of claim 11, wherein the functional filler is selectedfrom the group consisting of silicate minerals, wollastonite, talc,mica, kaolin, feldspar, nepheline syenite, nanoclays, platy fillers,nano-oxide materials, calcium carbonate, aluminum oxide, magnesiumhydroxide, basalt, zinc oxide, and combinations thereof.
 13. The coatingmaterial of claim 11, wherein the hydrophobic additive is selected fromthe group consisting of hydrophobic copolymer dispersants and saltsthereof, nonionic rheology modifiers, PTFE powders, and silicone surfaceadditive, high molecular weight polyolefin powder, polyolefin waxhydrophobic wax dispersions.
 14. The coating material of claim 11,wherein the content of the at least one acrylic latex resin is 25-55weight percent.
 15. The coating material of claim 11, wherein thecontent of the at least one functional filler is 35-50 weight percent.16. The coating material of claim 11, wherein the content of the atleast one hydrophobic additive is 1-20 weight percent.
 17. The coatingmaterial of claim 11, further comprising a pigment.
 18. The coatingmaterial of claim 17, wherein the content of the pigment is 3-15 weightpercent.
 19. (canceled)
 20. The coating material of claim 11, whereinthe coating exhibits a water infiltration depth of 120 microns or lessafter 4 hours at 60° C. and 95% relative humidity.
 21. The coatingmaterial of claim 11, wherein the coating exhibits a wet tensilestrength as measured according to ASTM D882 and/or ASTM D2370 of 80 psito 500 psi.
 22. The coating material of claim 11, wherein the coatingexhibits a wet adhesion strength as measured according to ASTM D903 of 2pli to 15 pli.
 23. A coating material, comprising: at least one acryliclatex resin; at least one functional filler having an aspect ratio of 3to 100; at least one hydrophobic additive; and a crosslinking agent;wherein the acrylic latex resin is selected from the group consisting ofhydrophobic resins, self-crosslinking resins, and crosslinkable resins;and wherein, when the coating material is applied as a 500 micron dryfilm thickness coating to a roofing substrate, the coating exhibits agreater dry tensile strength than a test coating on a roofing substrateapplied with an identical coating material without the at least onefunctional filler having said aspect ratio.